Project Overview
A dairy producer needed IPM to engineer gabletop packaging solutions for two related applications: a single-quart line project and a two-quart line project, each shaped by space constraints and demanding line requirements. Across the two applications, the lines had to manage filler discharge for two lanes of product, merge both lanes into a single lane for case packing, and maintain controlled product flow through the system.
The Problem
Fragile Cartons and Tight Handling Requirements
In both applications, paperboard cartons with a bottom seam made gentle handling essential throughout the line. Additionally, in each case, the filler discharged two lanes of product that had to be combined before feeding a single lane into the case packer. Fragile cartons, bottom seams, and lane-merging requirements created a risk of carton wear, seal damage, and inconsistent downstream flow.
Limited Space and Shutdown Discharge Constraints
Both applications were shaped by limited space. For the single-quart line, the customer had very limited room for the full line from filler through stretch wrapping. The two-quart line project also had to fit two production lines within a constrained space. In both applications, the lines had to accommodate the discharge of 72 cartons during a filler shutdown, even when product was already present through the system.
Throughput Demands and Performance Pressure
The two-quart line project combined limited space with a higher-performance requirement. The customer wanted to fit two production lines within the available space while improving on past gabletop line performance, which had been running below 40% OEE. The new system also had to support significant 3-pack volume and maintain higher case throughput with a case format prone to instability.
“This project required more than fitting equipment into the available space. The line had to protect fragile cartons, maintain consistent flow, and perform well beyond the customer’s previous gabletop lines. By designing the system around those demands, IPM delivered a solution that exceeded 85% OEE on each line.”
— Brad Breuker, Director of Applications & Business Development, IPM
IPM’s Solution
System-Level Flow Control
Across both applications, IPM addressed lane-merging and delicate handling with a Perpetual Merge. The system allowed products to be singulated while moving continuously forward, rather than relying on stop-and-start transitions at the merge point. This continuous forward movement reduced wear on the paper cartons and seals as two filler lanes were combined into a single-lane feed for case packing, supporting more consistent downstream flow.
Application-Specific Accumulation Strategy
IPM adapted the accumulation approach to the requirements of each line. In the single-quart application, space and budget constraints made a dedicated accumulation system impractical, leading IPM to use a tabletop conveyor to provide enough space for filler discharge during shutdown scenarios.
In the two-quart line project, IPM implemented a FIFO (first-in, first-out) vertical-style accumulation system to reduce the impact of micro-stops on machine centers and keep the filler running. IPM also used a V-Curve line design, with each piece of equipment carrying additional speed capability so the downstream system could support filler output rather than limit it. IPM engineered the lines around filler production requirements and backed it with a performance guarantee tied to filler output.
OEM-Neutral Equipment Selection
IPM evaluated case packing options based on the specific requirements of each line rather than pursuing a single OEM solution. In the single-quart application, IPM worked across multiple OEMs to identify a case packer with a compact footprint and stainless-steel construction that could fit the available space.
In the two-quart line project, IPM evaluated case packing options capable of handling significant 3-pack volume at the rates required for the target line design. IPM also investigated multiple accumulation alternatives to optimize line flow given the limited available space.
End-of-Line Uptime Protection
To help the single-quart system maintain flow during pallet exchange events, IPM designed and built a robotic palletizing system with a half-layer table that collated product and pre-staged the next row. The added case accumulation enabled pallet exchanges without micro-stopping production, supporting the uptime goals built into the overall line design.
The Result
Across both applications, IPM delivered gabletop line solutions tailored to the demands of each operation. In the single-line project, the line fit the available footprint while supporting delicate carton handling and shutdown discharge requirements. In the two-quart line project, the system supported significant 3-pack volume, reduced the impact of micro-stops, and improved efficiency over the customer’s prior gabletop lines, delivering more than 85% OEE on each line.
Key Project Data
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Line OEE Achieved
0 Cartons
Shutdown Clearout Requirement (Filler)
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Integrated Lines
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